CN114570817A - Thin-wall array bulge structure forming tool and forming method - Google Patents
Thin-wall array bulge structure forming tool and forming method Download PDFInfo
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- CN114570817A CN114570817A CN202210164855.2A CN202210164855A CN114570817A CN 114570817 A CN114570817 A CN 114570817A CN 202210164855 A CN202210164855 A CN 202210164855A CN 114570817 A CN114570817 A CN 114570817A
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- 238000000034 method Methods 0.000 title claims abstract description 48
- 239000000463 material Substances 0.000 claims description 37
- 238000003754 machining Methods 0.000 claims description 12
- 239000011248 coating agent Substances 0.000 claims description 7
- 238000000576 coating method Methods 0.000 claims description 7
- 239000003792 electrolyte Substances 0.000 claims description 5
- 230000008569 process Effects 0.000 abstract description 19
- 238000001125 extrusion Methods 0.000 abstract description 8
- 238000012545 processing Methods 0.000 description 7
- 238000013461 design Methods 0.000 description 5
- 238000005336 cracking Methods 0.000 description 4
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- 239000000956 alloy Substances 0.000 description 1
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D22/00—Shaping without cutting, by stamping, spinning, or deep-drawing
- B21D22/02—Stamping using rigid devices or tools
- B21D22/04—Stamping using rigid devices or tools for dimpling
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
- B21C51/00—Measuring, gauging, indicating, counting, or marking devices specially adapted for use in the production or manipulation of material in accordance with subclasses B21B - B21F
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D22/00—Shaping without cutting, by stamping, spinning, or deep-drawing
- B21D22/02—Stamping using rigid devices or tools
- B21D22/022—Stamping using rigid devices or tools by heating the blank or stamping associated with heat treatment
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D37/00—Tools as parts of machines covered by this subclass
- B21D37/10—Die sets; Pillar guides
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D37/00—Tools as parts of machines covered by this subclass
- B21D37/20—Making tools by operations not covered by a single other subclass
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- Thermal Sciences (AREA)
- Shaping Metal By Deep-Drawing, Or The Like (AREA)
Abstract
The invention relates to a forming tool and a forming method for a thin-wall array bulge structure, wherein the forming tool comprises a female die and a male die which are oppositely arranged; the female die and the male die conform to the shape of the thin-wall array to be formed, and the other surfaces of the female die or the male die except the highest position of the bulge structure corresponding to the thin-wall array are integrally removed by a certain thickness. The forming method comprises the following steps: designing the shapes of a female die and a male die according to the shape of the thin-wall array to be formed; removing a certain thickness on the whole of the other surfaces of the female die or the male die except the highest position of the bulge structure corresponding to the thin-wall array; and carrying out hot press forming on the thin-wall array bulge structure by adopting a hot press mode on the female die and the male die. The invention can well solve the problem that the thin-wall array bulge structure is easy to crack in the extrusion forming process, and greatly improves the quality of the formed product.
Description
Technical Field
The invention relates to the technical field of material punch forming, in particular to a forming tool and a forming method for a thin-wall array bulge structure.
Background
The press forming is a processing and forming method for obtaining parts with required shape and size by applying external force to plates, strips, pipes, profiles and the like by pressure and a die to cause plastic deformation or separation.
When the bulge structure is processed, the technical process is that the plate is subjected to plastic deformation by using pressure and a die, so that the part processing is realized. The forming die is generally designed to be fully attached according to the shape of a target part, namely, no gap exists among a female die, the part and a male die after final forming, so that the forming precision of the part is ensured.
When a thin-wall array bulge structural part (shown in the attached figure 1) is machined, the deformation of the material at the bulge is large, and macroscopically, the local elongation of the material is large. Use original general mould design, when the forming process later stage is close the coating film state, the mould is close complete rigidity restraint to raw and other materials plane direction, can cause the bulging department feed not enough when continuing to exert pressure, causes the fracture to lead to the part to scrap.
Disclosure of Invention
(1) Technical problem to be solved
The first aspect of the embodiment of the invention provides a thin-wall array bulge structure forming tool, which comprises a female die and a male die which are arranged oppositely; the female die and the male die conform to the shape of the thin-wall array to be formed, and the other surfaces of the female die or the male die except the highest position of the bulge structure corresponding to the thin-wall array are integrally removed by a certain thickness. The embodiment of the invention can well solve the problem that the thin-wall array bulge structure is easy to crack in the extrusion forming process, and greatly improves the quality of the formed product.
The second aspect of the embodiment of the invention provides a method for forming a thin-wall array bulge structure, which comprises the steps of designing the shapes of a female die and a male die according to the shape of a thin-wall array to be formed; removing a certain thickness on the whole of the other surfaces of the female die or the male die except the highest position of the bulge structure corresponding to the thin-wall array; and carrying out hot press forming on the thin-wall array bulge structure by adopting a hot press mode on the female die and the male die. The embodiment of the invention can well solve the problem that the thin-wall array bulge structure is easy to crack in the extrusion forming process, and greatly improves the quality of the formed product.
(2) Technical scheme
The embodiment of the invention provides a thin-wall array bulge structure forming tool in a first aspect, wherein a bulge structure is arranged on a thin-wall array, and the forming tool comprises a female die and a male die which are oppositely arranged; the female die and the male die conform to the shape of the thin-wall array to be formed, and the other surfaces of the female die or the male die except the highest position of the bulge structure corresponding to the thin-wall array are integrally removed by a certain thickness.
Further, the thickness removed should be no greater than the flatness of the thin-wall array to be formed.
Further, the thickness of the material removed from the surface of the female die or the male die is not less than 10% of the overall material thickness.
Further, the thickness on the female die or the male die is removed by adopting an electrolytic machining method.
Further, the roughness of the female die or the male die is not higher than 3.2Ra after a certain thickness is removed.
The second aspect of the embodiment of the present invention provides a thin-wall array bulge structure forming method, which is performed by using the thin-wall array bulge structure forming tool according to any one of the first aspect of the embodiment of the present invention, and the forming method includes:
designing the shapes of a female die and a male die according to the shape of the thin-wall array to be formed;
removing a certain thickness on the whole of the other surfaces of the female die or the male die except the highest position of the bulge structure corresponding to the thin-wall array;
and carrying out hot press forming on the thin-wall array bulge structure by adopting a hot press mode on the female die and the male die.
Further, the method for removing a certain thickness of the female die or the male die is as follows: firstly, designing a boss electrode structure corresponding to the shape of the thin-wall array, and coating an insulating protection material at the highest position of the bulge structure of each boss electrode corresponding to the thin-wall array; during electrolytic machining, the female die or the male die is connected with the anode of a power supply, and the boss electrode is connected with the cathode of the power supply; the electrolyte is conducted between the two, and then the power supply is switched on.
(3) Advantageous effects
The embodiment of the invention has simple structure and convenient use, can well solve the problem that the thin-wall array bulge structure is easy to crack in the extrusion forming process, and greatly improves the quality of the formed product.
Additional aspects and advantages of the invention will be set forth in part in the description which follows and, in part, will be obvious from the description, or may be learned by practice of the invention.
Drawings
In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings needed to be used in the embodiments of the present invention will be briefly described below, and it is obvious that the drawings described below are only some embodiments of the present invention, and it is obvious for those skilled in the art to obtain other drawings based on these drawings without creative efforts.
FIG. 1 is a schematic diagram of a typical structure of a thin-wall array bulge structural part in the prior art.
Fig. 2 is a schematic structural diagram of a forming tool in an embodiment of the present invention.
FIG. 3 is a schematic diagram of an exemplary configuration of thin-wall array bump structural components in an embodiment of the present invention.
Fig. 4 is a schematic structural diagram of a forming tool in an embodiment of the present invention.
In the figure: a female die 1 and a male die 2.
Detailed Description
The embodiments of the present invention will be described in further detail with reference to the drawings and examples. The following detailed description of the embodiments and the accompanying drawings are provided to illustrate the principles of the invention and are not intended to limit the scope of the invention, i.e., the invention is not limited to the embodiments described, but covers any modifications, alterations, and improvements in the parts, components, and connections without departing from the spirit of the invention.
It should be noted that the embodiments and features of the embodiments in the present application may be combined with each other without conflict.
The present application will be described in detail with reference to the accompanying drawings 1-4, in conjunction with an embodiment.
According to the forming tool for the bulge structure of the thin-wall array in the first aspect of the embodiment of the invention, referring to fig. 1, the bulge structure is arranged on the thin-wall array.
Specifically, referring to fig. 2, the forming tool includes a female die 1 and a male die 2 which are oppositely arranged; the female die 1 and the male die 2 conform to the shape of the thin-wall array to be formed, and the other surfaces of the female die 1 or the male die 2 are integrally removed by a certain thickness except the highest position of the bulge structure corresponding to the thin-wall array.
As described in the background art, when a thin-wall array bulge structural part is processed in the prior art, the bulge part has large material deformation, and macroscopically shows that the local elongation of the material is large. Use general mould design scheme, when the forming process later stage is close the coating film state, the mould is close complete rigidity restraint to raw and other materials plane direction, can cause the bulging department feed not enough when continuing to exert pressure, causes the fracture to lead to the part to scrap. In the embodiment of the invention, the female die 1 and the male die 2 are firstly designed into the shape which is in accordance with the thin-wall array to be formed, so that the thin-wall array which is in accordance with the shape requirement can be formed by the extrusion of the female die 1 and the male die 2. Secondly, the female die 1 or the male die 2 is integrally removed with a certain thickness except the highest position corresponding to the bulge structure of the thin-wall array, and after the design, when the post-closing state of the bulge structure of the die assembly thin-wall array of the female die 1 or the male die 2 approaches the close-to-die state in the forming process of the bulge structure of the die assembly thin-wall array, gaps are reserved among the female die 1, the thin-wall array to be formed and the male die 2, so that surrounding materials are allowed to be fed to the bulge stretching position during the subsequent pressure application, the problem that the thin-wall array to be formed cracks is effectively avoided, and the forming quality and the forming effect are greatly improved.
In conclusion, the embodiment of the invention has the advantages of simple structure and convenience in use, can well solve the problem that the thin-wall array bulge structure is easy to crack in the extrusion forming process, and greatly improves the quality of the formed product.
According to another embodiment of the first aspect of the invention, the thickness removed should be no greater than the flatness of the thin-wall array to be formed. The method is mainly used for avoiding the bulge structure cracking caused by local attachment and no gap due to error accumulation in the forming process, and when the removed thickness is larger than the flatness of the thin-wall array to be formed, the situation that the gap between the female die 1 and the male die 2 is small due to the flatness caused by the error accumulation and the material cannot move to the bulge stretching position does not exist.
According to another embodiment of the first aspect of the present invention, the thickness of the material removed from the surface of the female die 1 or the male die 2 is not less than 10% of the thickness of the whole material, which is mainly to ensure that the bulge structure is cracked due to local fitting and no gap caused by error accumulation during the forming process, and according to experience, the thickness of the removed material is not less than 10% of the thickness of the material, and meanwhile, the thickness of the removed material cannot be higher than the flatness requirement of the part, which is mainly to ensure that the formed bulge meets the use requirement.
According to one embodiment of the first aspect of the invention, the thickness on the female mould 1 or the male mould 2 is removed by means of an electrolytic machining process. The reason is that the female die 1 or the male die 2 usually adopts a local removing mode, if a conventional machining mode is adopted, the problem of sharp edges and acute angles exists, local protrusion exists, stress concentration exists in the forming process, and bulges crack, so that an electrolytic machining method is needed to realize local uniform removal, and the forming precision can be ensured.
According to one embodiment of the first aspect of the invention, the roughness of the female die 1 or the male die 2 after removal of a certain thickness is not higher than 3.2 Ra. The surface flatness is guaranteed to the greatest extent after the thickness, so that the surface flatness of the formed thin-wall array can be guaranteed, and the surface flatness meets the requirement. Of course, in the actual processing process, the roughness of the surface of the female die 1 or the male die 2 after removing a certain thickness may be 2.4Ra, 2.0Ra, etc., which may be determined according to the requirement.
Of course, in the actual processing, a certain thickness may be removed from the surface of the female mold 1, or a certain thickness may be removed from the surface of the male mold 2, which may be determined as required.
According to another embodiment of the first aspect of the present invention, referring to fig. 2, the embodiment of the present invention designs the male mold 2 according to the conventional general scheme, that is, completely conforms to the shape of the thin-wall array to be formed; after the female die 1 is designed according to the shape completely conforming to the thin-wall array to be formed, a certain thickness t is removed from the whole surface except the surface corresponding to the highest position of the corresponding thin-wall array bulge structure, wherein the thickness t is smaller than the flatness requirement of the surface of the thin-wall array to be formed. After forming, the highest position of the thin-wall array bulge structure is in contact with the female die 1 and the male die 2, namely the gap between the female die 1 and the male die 2 is the thickness d of the thin-wall array material, and the gap between the female die 1 and the male die 2 at other positions is the thickness d + the removal thickness t of the thin-wall array material, namely the total gap between the female die 1, the thin-wall array and the male die 2 is about 0-t, as shown in the attached figure 2, wherein h is the bulge structure height of the formed thin-wall array. Therefore, when the later period of the forming process is close to a mold-attaching state, the total gap among the female mold 1, the thin-wall array to be formed and the male mold 2 is about t, the surrounding materials are allowed to feed to the bulge stretching position when pressure is applied subsequently, and the problem of material cracking and scrapping is effectively avoided.
According to the second aspect of the embodiment of the invention, the thin-wall array bulge structure forming method adopts the thin-wall array bulge structure forming tool according to any one of the second aspect of the embodiment of the invention for forming, and the forming method comprises the following steps:
the method comprises the following steps: designing the shapes of the female die 1 and the male die 2 according to the shape of the thin-wall array to be formed;
step two: removing a certain thickness on the whole surface of the female die 1 or the male die 2 except the highest position of the bulge structure corresponding to the thin-wall array;
step three: and carrying out hot press forming on the thin-wall array bulge structure by adopting a hot press mode on the female die 1 and the male die 2.
According to the forming method provided by the embodiment of the invention, firstly, the female die 1 and the male die 2 are designed into the shape which is in accordance with the thin-wall array to be formed in the first step, so that the thin-wall array which is in accordance with the shape requirement can be formed through the extrusion of the female die 1 and the male die 2. And secondly, removing a certain thickness of the whole surface of the female die 1 or the male die 2 except the highest position of the bulge structure corresponding to the thin-wall array, wherein after the design, when the post-closing state of the bulge structure of the thin-wall array formed by closing the female die 1 or the male die 2 approaches the close-to-die state, gaps are reserved among the female die 1, the thin-wall array to be formed and the male die 2, so that surrounding materials are allowed to feed to the bulge stretching position during the subsequent pressure application, the problem of cracking of the thin-wall array to be formed is effectively avoided, and the forming quality and effect are greatly improved. And finally, carrying out hot press forming on the thin-wall array bulge structure by adopting a hot press mode on the female die 1 and the male die 2 to obtain the thin-wall array structure with good forming effect.
The forming method disclosed by the embodiment of the invention is simple and easy to implement and convenient to use, can well solve the problem that the thin-wall array bulge structure is easy to crack in the extrusion forming process, and greatly improves the quality of the formed product.
According to another embodiment of the second aspect of the invention, the method for removing a certain thickness of the female die 1 or the male die 2 is as follows: firstly, designing a boss electrode structure corresponding to the shape of the thin-wall array, and coating an insulating protection material at the highest position of the bulge structure of each boss electrode corresponding to the thin-wall array; during electrolytic machining, the female die 1 or the male die 2 is connected with an anode of a power supply, and a boss electrode is connected with a cathode of the power supply; the electrolyte is conducted between the two, and then the power supply is switched on. In the embodiment of the present invention, the female mold 1 or the male mold 2 that needs to remove a certain thickness may be subjected to the thickness removal operation, for example, taking the thickness removal of the surface of the female mold 1 as an example: firstly, designing a boss electrode structure corresponding to the shape of the thin-wall array, and coating an insulating protection material at the highest position of the bulge structure of each boss electrode corresponding to the thin-wall array; during electrolytic machining, the female die 1 is connected with the anode of a power supply, and the lug boss electrode is connected with the cathode of the power supply; the electrolyte is conducted between the two, and then the power supply is switched on. Therefore, electrolytic reaction is generated between the boss electrode and the female die 1 except the position coated with the insulating protection material, erosion is generated on the female die 1 connected with the anode of the power supply in the electrolytic reaction process, the surface of the female die 1 is gradually electrolyzed, and the required thickness structure is obtained. The ideal thickness and surface appearance can be obtained through electrolytic processing, and the processing process is convenient and easy to implement.
The following describes a forming tool and a forming method according to another embodiment of the present invention. Referring to FIG. 3, the embodiment of the invention adopts GH3230 thin-wall array bulge structure with the plate thickness of 0.6 mm.
Firstly, designing a female die 1 and a male die 2 according to the shape of a thin-wall array bulge structure to be formed, wherein the female die 1 and the male die 2 completely conform to the convex shape and the concave shape of the thin-wall array bulge structure respectively;
then, three-coordinate detection and a conventional measuring tool mode are adopted to determine that the error accumulated amount is about 0.05mm, the 10% size of the material thickness of the thin-wall array bulge structure is 0.06mm, therefore, the size range of the material thickness on the female die 1 is 0.06-0.2mm, on the premise of ensuring that the material of the female die 1 cannot crack, the smaller the size of the material of the female die 1 is, the better the size is, for the material with better plasticity, the removed material can be properly improved, and as the plasticity of the high-temperature alloy is better, the surface corresponding to the highest position of the bulge is determined, and the whole of other surfaces is removed by 0.1 mm;
then, electrolytic machining is used to remove the local material of the female die 1. The method comprises the following steps of firstly designing boss electrode structures corresponding to thin-wall array shapes, coating insulating protective materials at the highest positions of bulge structures corresponding to the thin-wall arrays of each boss electrode structure, and realizing that the highest positions of bulges of a female die 1 are blocked by the insulating protective materials in the electrolytic removal process, so that electrolytic reaction does not occur and removal does not occur. During electrolytic processing, the cathode film 1 is connected with the anode of a power supply, and the lug boss electrode structure is connected with the cathode of the power supply; electrolyte is conducted between the cathode film and the anode film, a power supply is connected, the cathode film 1 is dissolved under the action of an electric field, the shape of the boss electrode structure is reflected on the surface of the cathode film 1, and the machining is stopped after the surface of the cathode film 1 is removed by a certain thickness along with the electrolytic machining.
Finally, carrying out hot press forming on the thin-wall array bulge structure by adopting a common hot press mode;
after forming, the quality of bulge forming is judged by adopting a fluorescence detection mode, and the detection result shows that the bulge has no microcrack and through crack and has good surface quality. The highest position of the thin-wall array bulge is in contact with the female die 1 and the male die 2, namely the gap between the female die 1 and the male die 2 is 0.6mm, and the gap between the female die 1 and the male die 2 at other positions is 0.7mm, namely the total gap between the female die 1, the formed thin-wall array and the male die 2 is about 0.1mm, as shown in the attached figure 4.
Therefore, the forming tool and the forming method disclosed by the embodiment of the invention solve the problem of surface cracking in the forming process of the thin-wall array bulge structure, realize high-quality forming of the thin-wall array bulge structure, and can also be applied to large-curvature forming of other metal materials.
It should be clear that the embodiments in this specification are described in a progressive manner, and the same or similar parts in the embodiments are referred to each other, and each embodiment focuses on the differences from the other embodiments. For embodiments of the method, reference is made to the description of the apparatus embodiments in part. The present invention is not limited to the specific steps and structures described above and shown in the drawings. Also, a detailed description of known process techniques is omitted herein for the sake of brevity.
The above description is only an example of the present application and is not limited to the present application. Numerous modifications and variations could be made to the present disclosure by those skilled in the art without departing from the scope of the present disclosure. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present application should be included in the scope of the claims of the present application.
Claims (7)
1. A thin-wall array bulge structure forming tool is characterized in that the forming tool comprises a female die and a male die which are oppositely arranged; the female die and the male die conform to the shape of the thin-wall array to be formed, and the other surfaces of the female die or the male die except the highest position of the bulge structure corresponding to the thin-wall array are integrally removed by a certain thickness.
2. The tool of claim 1, wherein the removed thickness is no greater than the flatness of the thin-wall array to be formed.
3. The tool of claim 1, wherein the thickness of the material removed from the surface of the female die or the male die is not less than 10% of the overall material thickness.
4. The tool for forming the thin-wall array bulge structure as claimed in claim 1, wherein the thickness of the female die or the male die is removed by an electrolytic machining method.
5. The tool for forming the thin-wall array bulge structure as claimed in claim 1 or 4, wherein the roughness of the female die or the male die after a certain thickness is removed is not higher than 3.2 Ra.
6. A forming method of a thin-wall array bump structure, which is characterized in that the forming tool of the thin-wall array bump structure is adopted for forming, and the forming method comprises the following steps:
designing the shapes of a female die and a male die according to the shape of the thin-wall array to be formed;
removing a certain thickness on the whole of the other surfaces of the female die or the male die except the highest position of the bulge structure corresponding to the thin-wall array;
and carrying out hot press forming on the thin-wall array bulge structure by adopting a hot press mode on the female die and the male die.
7. The method for forming a thin-walled array bump structure as claimed in claim 6 wherein the method for removing a thickness of the female mold or the male mold is as follows: firstly, designing a boss electrode structure corresponding to the shape of the thin-wall array, and coating an insulating protection material at the highest position of the bulge structure of each boss electrode corresponding to the thin-wall array; during electrolytic machining, the female die or the male die is connected with the anode of a power supply, and the boss electrode is connected with the cathode of the power supply; the electrolyte is conducted between the two, and then the power supply is switched on.
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CN102107244A (en) * | 2009-12-23 | 2011-06-29 | 沈阳黎明航空发动机(集团)有限责任公司 | Method for forming thin-walled parts through stamping and drawing |
CN101879555A (en) * | 2010-06-23 | 2010-11-10 | 山东潍坊福田模具有限责任公司 | Die processing method for solving unevenness of vehicle door outer plate |
CN105170795A (en) * | 2015-09-09 | 2015-12-23 | 湖南大学 | Calculation method of variable blank holder force, facilitating formation, and drawing die using calculation method |
CN112427557A (en) * | 2020-11-12 | 2021-03-02 | 中国航空制造技术研究院 | Forming and shape-preserving heat treatment method for aluminum-based alloy complex-structure thin-wall component |
CN113878006A (en) * | 2021-11-18 | 2022-01-04 | 内蒙古第一机械集团股份有限公司 | Forming die and forming method for reinforcing ribs of sheet covering part |
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